Visions Becoming Reality

VDTC: The Worldwide One of a Kind VR Research Center Opens

Configuring Machinery with the Modular Principle

Really Controlling Virtual Machinery

IFFOCUSInteractive Human-Machine

2/2006

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Dear Readers,

2006 was an extremely eventful yearfor the Fraunhofer IFF. After nearlytwo years of planning and construc-tion, we were able to kick off ourexpansion, the Virtual Developmentand Training Centre VDTC. A visionbecame reality on November 22,2006, the day of its opening.More than 450 guests celebrated amarvelous party with us, full of sur -prises and tributes that we willremember for a long time. The opening of the VDTC is a signifi-cant event in our insti tute’s history.

This new building’‘s remarkable tech-nical facilities and equipment providesunique opportunities. We are especi-ally proud of our Elbe Dom in whichwe can reproduce virtual modelsdeceptively realistically on a large 360degree projection surface. With theVDTC, the Fraun hofer IFF has laid animportant cornerstone for Saxony-Anhalt’s sustainability as a center ofresearch. One can hardly imagineresearch and science or free enterpriseanymore without virtual technologies.

Today, complex technical systemshave an ever shorter life cycle, whichin turn requires rapidly adapting tochanged market situations. Now asbefore, time and cost factors are play-ing an important role.

This is precisely where the potential ofvirtual technologies unfolds. At theVDTC, we develop customized solu -tions that noticeably expand thepotentials of our client’s ventures andprojects. The new IFFOCUS presentsimpressive examples of successfulcollaboration with partners from re -search and industry. One immediatelythinks of the sectors of aviation ormechanical and plant engineering, yetvirtual technologies are increasinglyentering other sectors, e.g. medicaltechnology. Ever greater significanceis being attached to the issues oflearn ing and training in virtual envi-ronments.

Get to know another side of us: Thenew IFFocus will inform you about ourinstitute and the people who workhere, current news and joint projectwork with our partners from all overthe world. I wish you much enjoymentreading.

Yours,

Prof. Michael Schenk

Prof. Michael SchenkDirector of the Fraunhofer Institute for

Factory Operation and Automation© V. Kühne

Editor’s Page

News

6Opening of the Virtual Developmentand Training Centre VDTC Celebrated

Researchers Take Over the FormerCommercial Port

7Fraunhofer IFF and Jenoptik ConcludeCooperation Agreement

53rd GFA Spring Convention inMagdeburg

815 Years of Research for the RealWorld: 10th IFF Science Days

New Opportunities through EUSupport Programs

9VIRTUALIS: Engineering Safe Plants –Operating Plants Safely

3rd International INTUITION Networkof Excellence Work shop

10Open Days 2006: InternationalResearch Careers in Germany

Schavan Announces Further SupportIni tia tives for Esastern Germany

Run-up Project to BMBF InnovationCluster Starts in Magdeburg

11Haseloff Is Patron of the GuestLecture Series

Power from Rice Husks

Interview

12The Sky’s the Limit with FraunhoferKnow-howInterview with Richard Smyth, AirbusToulouse, Vice President SystemsGeneral

14On the Research Express to the RealWorldMarco Schumann

18Medical Technical Training in aVirtual LabWolfram Schoor, Dr. Rüdiger Mecke, Martina Rehfeld andDr. Kathrin Baldauf

22Virtual Machine Configuration Based on a Modular PrincipleDr. Tamara Nestorovic andRonny Franke

26Really Controlling Virtual MachinesMarco Schumann andTorsten Böhme

In this issue ...

Research and

Development

30PMO Services: The All-round Talentfor Industrial PlantsDr. Martin Endig andFrank Mewes

36Westermann Verlag Is Banking one-LearningHeike Kissner

38Augmented Reality in AircraftMaintenanceDr. Dieter Langer

42Euro pean Training Program for Young ResearchersDr. Eberhard Blümel

Sharp Minds

44New VDI State Representative forrSaxony-Anhalt in Office

How Virtuality Became Reality

45Doctoral Fellowship for IFF ComputerScientist

Successful Doctorate

New Director of the Institute ofLogistics and Material HandlingSystems

46New Head of Administrative Servicesat the Fraunhofer IFF

From Munich to Magdeburg for aDoctorate

Gallery

48Impressions of Researchand Technology

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Editorial Notes

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On November 22, 2006, Saxony-Anhalt’s Minister President WolfgangBöhmer opened the MagdeburgFraunhofer Institute’s new researchcenter. The VDTC provides clientsfrom business and industry virtual-interactive scenarios to plan, test andoperate technical systems, which canbe reproduced deceptively realisticallyon a large projection surface. At theceremony, the VDTC was honored asa “Landmark in the Land of Ideas”.More than 450 prominent guestsfrom politics, research and businessgathered to officially open the trainingand development center for virtualtechnologies. Prof. Wolfgang Böhmer,Minister Presi dent of the State ofSaxony-Anhalt and Dr. Ulrich Buller,President of the Fraunhofer-Gesellschaft, presented the symbolickey to Director Michael Schenk.Schenk also received his institute’saward as “Landmark in the Land ofIdeas” from the hands of Mike deVries, CEO of FC Deutschland GmbH.“Germany – Land of Ideas” is a natio-nal initiative sponsored by the Germangovernment and commerce and in -

dustry, represented by the GermanIndustry Association (BDI). The initiati-ve’s objective is to present an imageof Germany at home and abroad as acountry that is innovative, open to theworld and inspired. “It is a greathonor for us to be allowed to repre-sent Germany in the world as part ofthis initiative and, on top of that, onsuch an important day for us,” said apleased Prof. Michael Schenk. To hissurprise, another honor followed: TheRegional Conference awarded itsRegional Prize to the Director for hiscontributions in making Magdeburg acenter of research. The large laser-based projection system was present -ed to the public for the first time. SixJenoptik laser pro jec tors displayedvirtual models of complex machineryand plants on a 360 degree projectionsurface. Jenoptik and Fraunhoferspecialists jointly designed the largelaser-based projection system andintend to develop it further in thefuture. Numerous other research andindustry partners also displayed greatinterest in the VDTC. On the day of itsopening, the “Virtual EngineeringStrategy Group” was constituted. It

will closely support developments atthe VDTC in the future and devoteitself to the latest research findings inthe field.

At the VDTC, the Fraunhofer Institutefor Factory Operation and AutomationIFF pursues applied research in thefield of virtual engineering for plan-ning, testing and operating technicalsystems. Contractual partners andclients include large internationalconcerns, regional small and medium-sized enterprises and contractingauthorities. Close collaboration ismaintained with academic and non-academic research organizations inMagde burg, especially Otto vonGuericke University and the MaxPlanck Institute for Dynamics ofComplex Technical Systems, theLeibnitz Institute of Neurobiology andthe Leibnitz Institute of Plant Geneticsand Crop Plant Research inGatersleben. On the basis of virtualand augmented reality, specialistsworking together interdisciplinarilydevelop customized solutions such asvirtual-interactive training for speciali-zed staff.

Researchers Take Overthe Former CommercialPortFrom apprentice glass grinder tofamous scientist – the history ofJoseph von Fraunhofer’s career readslike an exciting novel. Today, Europe’slargest organization for applied rese-arch is named after him: The

Opening of the Virtual Development and Training Centre VDTC Celebrated

Roland Sahr, Deutsch Bank AG; Prof. Michael Schenk, Director of the Fraunhofer IFF;Minister Presi dent Wolfgang Böhmer and Mike de Vries, CEO of FC Deutschland .l. to r.).

The VDTC is now a landmark in the “Land of Ideas”. © V. Kühne

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“Developing Competence in Real andVirtual Work Systems”.Collectively, these technologies aregateways to considerably expandedperception, which can be used as thebasis to develop competence on thebasis of experience. Since virtual tech-nologies have not been predominantlydeveloped from the perspective ofqualification and competence training,research in work and occupationalscience and didactic reflection are justas necessary as corresponding techno-logical advances in virtual worksystems. More and more, basic andadvanced educational and trainingprograms that integrate virtual worksys tems as an educational medium areattracting attention.

Along with interesting presentationsand the opportunity to exchangeideas with specialists working interdis-ciplinarily, convention attendees willbe able get to know the FraunhoferIFF Virtual Development and TrainingCentre VDTC.

For detailed information on theconvention program and registrationmaterials visit www.gfa-online.de.

Specialists from Jenoptik and theFraunhofer Institute in Magdeburgjointly engineered this large-scale laserprojection system. The experts intendto work together on developing it fur -ther and developing new fields ofapplication.

To this end, Jenoptik’s Chairman ofthe Board Alexander von Witzleben,Jenoptik LDT CEO Jürgen Meyer andFraunhofer IFF Director MichaelSchenk signed a cooperation agree-ment in Magdeburg in October.Central points of cooperation will bevisualization principles of stereoscopiclaser projections and the developmentof short demonstration films for in -dustrial applications.

53rd GfA Spring Con -vention in Magdeburg

Every year at the spring convention ofthe Gesell schaft für Arbeitswissen -schaft e.V. (GfA), researchers discusscurrent trends and developments inthe fields of ergonomics, vocationaltraining research and engineeringmedia research. This year’s GfA springconvention will be held at theMagdeburg Fraunhofer Institute fromFebruary 28 through March 2, 2007and will be devoted to the topic of

Fraunhofer-Gesell schaft. That is not allthough. The famous scientist andbusinessman has been immortalized inMag deburg’s cityscape. Since Sep -tember 2006, his name gleams on thesign for “Joseph-von-Fraunhofer-Strasse” in the newly developed Portof Science. Along with Fraunhofer,Werner Heisenberg and Niels Bohrhave also been immortalized on streetsigns in the Port of Science. A livelyneighborhood for living and working isdeveloping in the Port of Science.What was once a cargo terminal isevolving into a new neighborhoodwith high level insti tutes and businessincubators embedded in a lively neigh-borhood with apartments, servicecenters and recreational opportunities.The first boat has already dockedthere: The new building housing theVirtual Development and TrainingCentre VDTC is located in the imme-diate vicinity of the Max PlanckInstitute for Complex DynamicSystems.The choice of name makes significantchanges in the city of Magdeburgapparent. Research and science inparticular have become extremelyimportant in recent years.Development has been so fast pacedand vigorous that the structural trans-formation from a city of heavy machi-nery manufacture to a city of appliedresearch is clearly observable.

Fraunhofer IFF andJenoptik ConcludeCooperation AgreementThe heart of the new Fraunhofer re -search center in Magdeburg’s Port ofScience is its round testing facility. SixJenoptik laser projectors display virtualmodels of complex machinery andplants on a 360 ° projection surface, awhite cylinder made of curved andperforated aluminum extending overan area of approximately 330 m2. Theirremarkable brilliance of colors, sharp -ness and intensity make the three-dimensional reproductions captivating.

Fraunhofer IFF and Jenoptik concluding the cooperation agreement: Dr. Jürgen Meyer, CEO ofJENOPTIK LDT GmbH; Alexander von Witzleben, Chairman of the Board of JENOPTIK AG

and Prof. Michael Schenk, Director of the Fraunhofer IFF (l. to r.). © P.Förster

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New Opportunitiesthrough EU SupportPro gramsThe European Union offers a multi-tude of programs to support the workof small and medium-sized enter -prises. How can one obtain an over-view of current programs and guideli-nes though? How can one best takeadvantage of the opportunities?

The project smE-MPOWER set itself thetask of identifying opportunities for EUsupport for more intensive researchwork in companies and providingsupport throughout the entire devel -opment process. With partners fromGermany, Great Britain, France,Ireland, Israel, Lithuania, Romania, theSlovak Republic, Switzerland andCyprus, the project provides a connec-tion to an attractive internationalnetwork.

SmE-MPOWER is intended to helpenterprises define potentials for inno-vation to identify pertinent supportinstruments. Professional coachinggenerates project ideas that aresupported through the final proposal.Active participation in special interestgroups enables interested enterprisesto profit from the knowledge of otherenterprises and exchange ideas.Participation in virtual discussionforums enables enterprises to recruitone or more partners for their inno -vation project and carry out a jointresearch project. The heart of thesmE-MPOWER service is an individualcoaching process that helps navigatethe hurdles of European proposalsubmission.

Small and medium-sized enterprisescan continue to take advantage ofsmE-MPOWER’s free services to trans-form their innovative ideas intoproject proposals until October 31,2007.

For more information visit www.sme-mpower.net.

At the same time as the 10th IFFScience Days, the Fraunhofer IFF willbe celebrating its 15th anniversary inJune 2007, a splendid occasion togather at the Fraunhofer IFF to cele-brate together, to look back at pastaccomplishments and above all totake a look forward, to develop newideas and to initiate joint projects.Clients, partners and friends will becoming to Magdeburg to pick up thelatest trends in research at profes -sional conferences, workshops andindustry seminars and to acceleratetheir transfer to industry.

Two international conferences areplanned for the 2007 IFF ScienceDays. Resuming the direction of pastyears, there will also be a conferenceon “Virtual Reality and AugmentedReality for Engineering, Testing andOperating Technical Systems” in2007. The newly opened VirtualDevelopment and Training CentreVDTC with its diverse VR and AR labsnot only enables elucidating thepotentials of virtual technologies intheory but also experiencing them inpractice. As in past years, we are notonly explicitly appealing to researchers

but also experts from companies tointensify the dialog between researchand business. The second conference will deal with“Logistics: Intelligence in Manufac -turing and Transportation” and thustake up another focus of research atthe Fraunhofer IFF. It will concentrateon intelligent logistics solutions thatare based on state-of-the-art com -muni cation, telematics and satellite navigation technologies and suitablefor controlling the increasing flows ofgoods and rising demands in theinternational exchange of goods.Additionally, there will be workshopsand indus try seminars on other fieldsof Fraunhofer IFF research such asauto mation and produc tion and plantmanagement.

For more information visitwww.iff.fraunhofer.de.

15 Years of Research for the Real World10th IFF Science Days

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INTUITION, a research networksupported by the European Unionconcentrates on the use of virtual andaugmented reality to design futureworkspaces. Researchers are workingon means to transfer research findingsto corporate practice as quickly aspossible. In turn, the applicationopens insights into how virtual envi-ronments must be constituted so thathuman beings work in them optimallyand also accept them as a tool.

The Technical University of Athens iscoordinating the INTUITION Network.The 58 organizations involved comefrom eleven different sectors, inclu-ding the aviation, automotive andutilities industries. The Fraunhofer IFFin Magdeburg has also been amember since September of last year.

In November 2006, the network part-ners gathered at the 3rd Inter nationalINTUITION Workshop where the rese-archers discussed current issues sur -rounding the issue of workspacedesign.

For detailed information on thenetwork visit www.intuition-eunetwork.org/.

VIRTHUALIS: EngineeringSafe Plants – OperatingPlants Safely

Preventing accidents at large indus trialfacilities has utmost priority. As a rule,up to 90 percent of serious accidentscan be attributed to human errorsduring high risk manufacturingprocesses such as in the chemicalindus try.

VIRTHUALIS (Virtual Reality andHuman Factors Applications for Impro -ving Safety), an international consor-tium of 43 partners is working onmeans to reduce dangers in manufac-turing and storage facilities.Fraunhofer researchers from theVirtual Devel opment and TrainingCentre VDTC in Magdeburg are alsoinvolved in the project.

The focus is on dangers that areprimarily triggered by human behav -ior, so-called “human factors”. Theobjective of VIRTHUALIS is to identifyweak points in a facility’s safety at anearly stage, to increase safety and toorganize safety aspects transparentlyin order to safely manage criticalsituations.

As part of VIRTHUALIS, researchersare developing a novel technologyplatform that brings problems withhuman factors and characteristics oftechnical pro cesses together in avirtual development environment.

Thus, safety-critical process states willbe made easily comprehensible forpersonnel (operators, safety manag -ers). In the virtual environment, theconsequences of human actions willbe immediately recognizable, trans -parently traceable and reproducibleanytime. It will be possible to alreadyclearly identify and eliminate safetyrisks in the phase of facility design.One model application is virtual fire-fighting by simulating different hazar-dous situations. The results of theVIRTHUALIS project are especially inte-resting for assessing risks and pre -venting and analyzing accidents. Sincethe researchers involved are workingtoward reducing accidents and indi -vidual damages in hazardous indus -tries, increasing the availability ofplants throughout the entire produc-tion life cycle and reducing day-to-daysafety expenses, VIRTHUALIS willgreatly benefit plant manufacturersand plant operators.

For more information visitwww.virthualis.org

3rd International INTUITION Network ofExcellence Work shop

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economic success and hold their ownagainst the global competition fortalent and young professionals,eastern German regions need inter -nationally excellent research centers,”said Schavan. The program’s firstround “Centers of Inno vationCompetence” has already started: Six centers have supported groups ofyoung researchers since 2005. “Thesuccesses of the first round of supportdemonstrate that the approach selec-ted is right. The concept is takingoff,” stated the Minister approvingly.

For more information on the innova -tion initiative Entrepreneurial Regionsvisit http://www.unternehmen-region.de.

Run-up Project to BMBFInnovation Cluster Startsin Magdeburg

In preparation for the innovationcluster Virtual Development andTraining (VIDET) in the German gov -ernment’s high-tech offensive, theFraun hofer IFF in Magdeburg is begin-ning work on the run-up project onInterface Configuration for IntegratedProcess Chains in the Developmentand Manufacture of MechatronicSystems.

The objective of the planned innov -ation cluster VIDET is to promoteinterdisciplinary research and applicati-ons in the field of virtual tools for theplanning, development and operationof products and systems by networ-king industry, academic and non-academic research organizations. Theinno vation cluster is intended tocontribute to the development andutilization of methods suitable forapplication and to create tools thatsupport the integrated utilization ofvirtual design and virtual realitythroughout the entire product lifecycle and empower small andmedium-sized enterprises to place

The Fraunhofer IFF presented itsEuropean research net works at theOPEN DAYS – Euro pean Week ofRegions and Cities in October. At theopening of the event, Mi nister ofEconomics and Labor Reiner Haseloffemphasized the significance of astrong research scene for our state’slong-term and sustainable economicdevelopment: “For enterprises in ourstate, local research and developmentcompetence is a factor crucial torapidly launching innovative products

and services on the market.”Prof. Michael Schenk, Director of theFraunhofer IFF, described how broadlythe institute is anchored in Europe’sinternational research scene:“Through numerous European re -search projects and membership in networks of excellence and compe-tence, the Fraunhofer IFF is instrumen-tal in bolstering Magde burg’s reputa-tion as a center of state-of-the-artresearch.” The Marie Curie program“ResearchTraining @VDTC” has madethe VDTC an international center ofresearch where young researchersreceive advanced qualification in thefield of virtual engineering.

Some sixty young researchers, doc -toral students, graduate students andstu dents attended the event at theFraunhofer IFF. Presentations weregiven on European research projectsand international researchers reportedon their experiences, speaking abouttheir own international researcherbiographies. Project managers fromthe Fraunhofer IFF and internationalpartners presented pro jects currentlyongoing at the research institute suchas Research Training @VDTC,VIRTHUALIS, HILAS, CADPIPE andsmE-MPOWER.

Schavan AnnouncesFurther Support Initiativesfor Eastern Germany

On the occasion of the kick-off ofEastern Innovati on Week, FederalMinister of Research Annette Schavanannounced twelve initiatives theMinistry of Education and Research(BMBF) will be supporting with up to250,000 euros apiece in the secondround of its program “Centers ofInnovation Competence: CreatingExcellence – Securing Talent” startingin early 2007. Two researcher teamsapiece will be from Brandenburg,Meck len burg-Western Pomerania andThuringia and three researcher teamsteams apiece will be from Saxony andSaxony-Anhalt, including one at theFraunhofer IFF in Magdeburg.

The program is part of the innovati on initiative “Entrepreneurial Regions”.The objective of the program is tosustainably establish high-level re -search centers in eastern Germany.International orientation, entrepre -neurial strategy and innovative ap -proaches to securing the next genera-tion are intended to generate lastingimpulses in the new states. “In orderto establish clusters with long-term

Open Days 2006: International Research Careers in Germany

Talking shop: Bartlomiej Arendarski and CarloBelardinelli (l. to r.) are two of the twelve Marie

Curie Fellows at the Fraunhofer IFF.© V. Kühne

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In their project, the researchers intendto analyze in detail the combustionbehavior of rice husks and otherbiomass typical for Vietnam such asreeds or sugar cane. The researchersare especially interested in whetherconventional fuels such as coal oflesser quality can be mixed withbiomass in the fluidized bed. “Thesestudies are particularly relevant for theVietnamese market. They are aimed atfinding low cost alternatives to expen-sive fossil fuels. The environmentalpollution generated by landfillingwaste will be reduced considerably,”according to Dr. Lutz Hoyer whoheaded the team at the Fraunhofer IFFthat developed the system. Dr. PhamHoang Luong, Deputy Director ofHanoi University of Technology,commented: “Our university isinvesting right now in lab equipmentfor experimental and educationaloperation. In the future, we will trainprospective engineers on the fluidizedbed system. Hence, we are thrilledabout the collaboration with theMagdeburg Fraunhofer Institute.”

For more information visit www.iff.fraunhofer.de

developments of new products orservices in dynamic markets evenbetter. Therefore, a particular priorityis enabling small and medium-sizedenterprises to utilize the methods ofvirtual product development, virtualprocess engineering and VR basedtraining.

Based on the extensive preliminarywork of the Fraunhofer IFF and itscooperati on partners, the run-upproject is a self-contained phase inpreparation to the innovation clusterVIDET. On the one hand, the resultswill be of use separately and, on theother hand, they will create importanttechnical and organizational prerequi-sites to VIDET.

Haseloff Is Patron of theGuest Lecture Series

In 2006, Saxony-Anhalt Minister ofEconomics and Labor Reiner Haselhoffassumed the patronage of the Fraun -hofer Guest Lecture Series “VirtualReality: Human and Machine inInteractive Dialog” for the first time.

The annual lecture series at whichhigh profile speakers from businessand research report on the use of VRand AR technologies in their compa-nies and institutes was held for thethird time.

Dr. Christoph Gümbel, Head of theVirtu al Vehicle Department, spoke on“How Virtual Reality Brings DigitalPrototypes to Life”. Dr. Dieter Langer,Project Manager in Military AirSystems at EADS Deutschland GmbH,described how augmented reality isused for aircraft maintenance. Hispresentation is printed here, startingon page 38. All the presentationsfrom the Guest Lecture Series havebeen collected in a volume of procee-dings. This publication (ISBN-10 3-8167-7256-0) can be ordered fromthe Fraunhofer IFF.

The fall 2007 Guest Lecture Seriesfrom October 24 through December 5will be held at the VDTC at Josef-von-Fraunhofer-Strasse 1. Minister ofEconomics and Labor Haselhoff hasagreed to be the patron of the fourthyear of this event too.

For more information visitwww.vdtc.de

Power from Rice Husks

Up to now, residual products fromVietnamese rice cultivation have beendisposed of as waste. Rice husks holdtremendous potential as energythough. Contracted by the Universityof Hanoi, Magdeburg Fraunhofer re -searchers developed a plant thatburns this biomass in a circulating flui-dized bed combustion reactor (CFBR).

The specialists at the Fraunhofer IFFand Hanoi University of Tech nologynow intend to jointly research howwell energy can be recovered from thematerial. Initial tests in the experi -mental plant were run in Magdeburgin the summer. In October, the CFBRwas started up in Hanoi for the firsttime. The Fraunhofer Institute forFactory Operation and Automation IFFand Hanoi University of Technologyare now drawing up a cooperationagreement on joint research projects.

Researchers from Magdeburg and Hanoi are researching the recovery of energy from biomass.

© V. Kühne

Dr. Reiner Haselhoff, © V. Kühne

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Perhaps you could provide one ortwo concrete examples?

The Fraunhofer IFF’s years of experi-ence in the field of RFID is verydemonstrative. In 1999, when hardlyanyone was familiar with and usingthis technology, the institute imple-mented a tool management system atAIRBUS Germany with which AIRBUSmonitors the use of tools at variousairlines and service providers’ facilitiesall over the world. Making informa-tion on tool type, service operations,cali bration and certificates availabledirectly on an object reduced cycletime by nearly 20 percent and mini -mized the work to document everyoperation with an electronic mainte -nance history file.

Another example is optical 3-D met -rology. Stressed-skin fuselages areassembled with riveted joints. Forsafety reasons, tremendous demandsare made on the precision of theseriveted joints. Several thousand rivetedjoints have to be inspected for eachstressed-skin fuselage. This was donemanually by workers who inspectedevery riveted joint for damage andused their thumbs to check whether aset head projected the specifiedamount. The Fraunhofer IFF replacedthis intensely subjective and timeconsuming inspection method with afully automatic optical inspection sys -tem. This inspection sys tem is inte -grated directly in the assembly line,allows inspecting quality 100 percentand has no effect on cycle time. Sincethe riveted joints are inspected im -mediately after being set, reworkingwas reduced by approximately 80percent.

How did this close relationshipbetween Airbus and the FraunhoferIFF in Magdeburg come about?

We completed some projects with thespeci alists from Magdeburg in recentyears. These projects were a realenrichment for Airbus. The outcomewas customized solutions for quiteindividualized tasks. The researcherswere able to put themselves in ourposition remarkably well. Everytime Ivisited, I was enormously impressed bythe degree to which work at theFraunhofer IFF is oriented towardprocesses and results. This is especiallyimportant considering how complexprocesses have become in today’sindustrial world. The Magdeburg re -searchers never go just halfway. Theyhave everything industry needs – wevalue that.

An interview with Richard Smyth,Airbus Toulouse Vice PresidentSystems General and Head of aTransnational Developer Team.

Airbus and Fraunhofer. Two bignames and an interesting constella-tion. What relationships do you seebetween these two organizations?

Compared to low-price countries,Germany and France need ampletechnological competence to securetheir leadership and remain competi-tive. Airbus needs strong researchpartners. We feel very connected toFraunhofer. Together, we have verysuccessfully completed some extreme -ly interesting projects in the widestvariety of specialized fields. We havedeveloped especially close relationswith the Magdeburg Institute in par -ticular.

The Sky’s the Limit with FraunhoferKnow-how

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And in the field of virtual reality?

The specialists at the Fraunhofer IFFhave developed a virtual-interactiveapplication, which assembly per -sonnel, mechanics and trainees canuse to learn how to execute particularmanufacturing and servicing jobs forthe Airbus A320 aircraft family. Theeducational contents reproducedinclude the installation and removal ofthe aileron control unit. Furthermore,trainees can virtually check the oillevel and change the oil in the int -grated drive generator of CFM56engines and complete a course on theinstallation and removal of the auxili-ary power unit. On the one hand, theeducational system is an optimal aidto generate better general under -standing of the overall technicalsystem and its components’ interrela-tionships and interactions. On theother hand, selected tasks can betaught in great detail and an aircraftdoes not have to be made availableextra to do so.

What significance will virtual tech-nologies have in the future?

By incorporating real interdependen-cies, virtual reality can be used tointervene in a process very early onbecause situations can be evaluatedmuch more precisely. In the nearfuture, no development process willget around this. In this respect, this

Brief CV

Richard Smyth, born on December 18,1941

1960-1966 Studied at the Technical University ofBerlin, majoring in AircraftEngineering and Engines

1966-1982Engineer at Airbus Deutsch landGmbH, formerly the Verei nigte Flug -technische Werke (VFW), in Bremen

Development engineer for engine in -stallations, later head of the enginedepartment

Studies on engine developments andinstallation for civilian aircraft (VFW614) and military aircraft (Tornado,EFA) and Transall C160. Later testingof new Airbus engines in Toulouse,France.

1982-1995Transfer to Airbus Industrie inToulouse, head of the engine depart-ment at Airbus Industrie

1995-2001Return to Germany, DaimlerChryslerAerospace Airbus in Hamburg

2001Airbus Deutschland GmbH, Director ofSystems Development

2001-2006Airbus Toulouse, Vice PresidentSystems General, head of a trans -national development team

alone already makes it possible topredict that virtual reality will play anextremely important role. Integratingvirtual-interactive models in everyphase of the product life cycle – i.e. indevelopment, engineering, testing andoperation – will become an entirelynormal procedure . This is why I consider the VDTCfundamentally important: A corner-stone for modern and sustainableGerman industry is being laid here inMagdeburg.

We’ve spoken about joint projectsin the past and the future signifi-cance of virtual reality in general.Will there again be joint projects inthe future too?

I’m sure of that. At the moment, veryconcrete talks are underway betweenAirbus and the Fraunhofer inMagdeburg. At this time, I’ll onlyreveal this much: The competencies inthe field of transponder-supportedlogistics and virtual reality are extraor-dinarily interesting for us. By the way,we are connected by even far morethan these business relationships.We’ve come to appreciate each otherthrough our joint project work inrecent years. I’m always glad to returnto Magdeburg again and again, espe-cially to the Port of Science on theElbe. You can stick your finger in thewater and know the same water flowsto us in Hamburg.

The Airbus A320 aircraft family. © Airbus S.A.S.

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On the Research Express to theReal WorldMarco Schumann

ViVERA, the Virtual Network of Competence for Virtual and Augmented Reality, has beenaround for two years. Its objective: Transferring research findings to the business world as rapidly as possible. ViVERA means “It’s alive!” Nomen est Omen – a particularly lively partnership is the distinctive feature of the research network with the unusual name. Proof of this is the many and diverse activities carried out by the partners – six Fraunhofer Institutesand their partner universities – in the first two years of the project.At the Fraunhofer IFF VDTC, work is being done on basic technologies and speci fic applied research. As the lead managing institute, it especially cultivates networking between the part-ners.

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Basic technologies include self-con -tained virtual reality functionali tiesthat can be used as the foundationfor development in different areas ofapplication. The ViVERA con sortiumhas launched a total of seven basictechnologies. Two of them are cur -rently being implemented at theFraunhofer IFF. The process “Gene r -ation of Models for VR Applications”employs a new system to generatevirtual models. It not only automati-cally records geometry but also color -ation (texture). One important featureis the visualization of objects forwhich 3-D CAD models do not exist.Applications for this are, for example,the scanning of tissue structures inmedicine or the restoration of histori-cal buildings in archi tecture. The2/2005 issue of IFFocus alreadypresented this method.

The second basic technology devel -oped at the Fraunhofer IFF “Interfacesto Systems for 3-D Model Genera -tion” allows transferring and auto -matically postprocessing 3-D CADmodels from commercially availableCAD systems. Among others, theseinclude ProEngineer, CATIA V5, SolidWorks and UniGraphics NX. Thismakes it possible to transfer thegeometry of 3-D ob jects and theirhierarchical structure to a virtualmodel. Moreover, the tool supportsdifferent levels of detail that can beused to optimize visualization. Thus,since the CAD data is often alreadyavailable in companies, this techno-logy is a basic prerequisite to costeffectively generating virtual models.

Another emphasis of ViVERA is theexamination of specific industry issues.The automotive in dustry, mechanicaland plant engineering, medical tech-nology and shipbuilding figure inprominently. In ViVERA, the team ofexper ts at the Fraunhofer IFF isconcentrating on the sectors ofmechanical and plant engineering.The objective is to enable small and

medium-sized enterprises in particularto access state-of-the-art VR and ARtechnologies. To do this, already de -veloped basic technologies are beingapplied and developed further accord -ing to concrete industry requirements.The outcome will be the creation of atotal of nine demonstra tors in theViVERA Network by the fall of 2007.Two of these will in turn have beendeveloped at the Fraunhofer IFF. Each will clarify one typical industryapplication of virtual technologies.Thus, they are intended to convinceother com panies to take advantage ofthe potentials of these new technolo-gies for themselves.

The work on the “Virtual Control”demonstrator has progressed so farthat a machine manufacturer isalready using the solution in its realwork (cf. IFFocus 2/2006, p. 26). Theidea involves coupling a real CNCcontroller with the virtual model of aheavy machine tool. This enablestesting the control programs at a timewhen the real ma chine is still being

set up. This link with a real controlerproduces an extremely realistic userscenario, ideal for the qualificationand advanced training of machineoperators. In the spring of 2006, thedemonstrator was presented at one ofthe world’s biggest trade shows forCNC machine tools in Shanghai andat the leading trade fair for computerinnovations, the CeBit in Hannover.

The second demonstrator “VirtualPlant” is currently still in development.To this end, the visualization ofprocess engineering parameters isbeing implemented, i.e. dynamiccharacteristics such as temperatureand presssure. What is more, thesignificant process flows are beingrepresented in a VR model. A movingbed reactor that reforms biogenicgases is serving as a model. A systemof mathematical equations was de -vised to describe functional perfor-mance. This system of equations isbeing built upon to simulate themoving bed reactor’s performance.

Simulation of a combustion chamber: Representation of pressure distribution.

Partner networking is another empha-sis in the project work. Last year, theFraunhofer IFF pursued two coopera -tions in particular. The Fraunhofer IFFtook advantage of the experience ofits partner in Stutt gart for the “VRSupported Engineering Workstation”.Virtual reality extends and optimizesan engineer’s workstation. Extremelylow-noise computer and projectorconcepts are applied to do this.Another component is a cost effectiveoptical tracking system that detectsthe position of the new, lightweightinteraction devices. The VR softwaredeveloped at the Fraunhofer IFF torepresent visual-interactive trai ningcontents is presently being adapted tothe new hardware to support expand -ed interaction techniques.

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The second cooperation relates to theuse of the visualization library OpenSGand the application Avalon based onit. The software developed by theViVERA partners in Darm stadt wastested at the Fraunhofer IFF. This willmake it possible in the future to use abasic tech nology “Photorealistic ImageGene ration in Real Time” developedin Darmstadt in combination with thelaser projection system at theFraunhofer IFF VDTC. Developed bythe specialists at the Fraunhofer IGDand presented for the first time inMarch 2006 at the computer tradefair CeBIT, this technology can beused to interactively present photo -realistic representations. This not onlymakes the technology interesting fordesign reviews but also for interactiveand functional 3-D mo dels.

The visualization is still being finetuned at present. The results from theflow simulation system (Fluent) willalso be integrated in the near future.In order to ensure components andtheir models are interchangeable, aprocedure is being developed todescribe components and theirconnected simu lations. A fluidizedbed combustion reactor is being usedas a validation model. The outcome ofthe developments will enable superim-posing a visualization of process par -ameters in the 3-D model of the reac-tor. This representation is intended tosupport communicati on betweenengineers and operators to betterjointly coordinate and optimizeprocess parameters.

Virtually engineering an assembly process is no problem at the immersive engineering workstation . © V. Kühne

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In particular, delving more deeply intofields of application is planned for thecoming year. In addition, a knowledgestorage system will be generated,which compiles all relevant projectexperiences. Thus, other enterprises

will also be able to utilize the resultsof the ViVERA Net work’s research.

Contact:Marco SchumannCentral ViVERA OfficeTel. +49 (0) 391/4090-158Fax +49 (0) 391/4090-115Marco.Schumann@iff.fraunhofer.de

Laser projection in the Elbe Dom at the Fraunhofer IFF VDTC. © P. Förster

Partners in the ViVERA Network

– FraunhofereInstitute for ComputerGraphics Research IGD inDarm stadt

– Technical University of Darmstadt

– Fraunhofer Institute for ComputerGraphics Research IGD-R inRostock

– University of Rostock

– Fraunhofer Institute for ProductionSystems and Design TechnologyIPK in Berlin

– Technical University of Berlin

– Fraunhofer Institute for MachineTools and Forming TechnologyIWU in Chemnitz

– Technical University of Chemnitz

– Fraunhofer Institute for IndustrialEngineering IAO in Stuttgart

– University of Stuttgart

– Fraunhofer Institute for FactoryOperation and Automation IFF inMagdeburg

– Otto von Guericke UniversityMagdeburg

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Medical Technical Training in aVirtual LabWolfram Schoor, Dr. Rüdiger Mecke, Martina Rehfeld (Fit-Bildungs-GmbH) and Dr. Kathrin Baldauf (FAN gGmbH)

Once they have completed their basic training,medical technical laboratory assistants or MTLAfirst have to familiarize themselves with their sphere of activity. Ultimately, every specializedfield of medicine has its own methods. In Magde-burg, a new training model has been started,which uses virtual models from the Fraunhofer IFFVirtual Deve lop ment and Training Centre VDTC tointroduce MTLA to their specific field.

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Magdeburg is an internationally recognized center of neuroscientificresearch. Some young and innovativeenterprises have established theCenter for Neuroscientific Innovationand Technology ZENIT. They collabo-rate closely with the UniversityHospital and the Leibniz Institute forNeurobiology (IfN), home of Europe’sfirst 7 Tesla magnetic resonancetomograph. One of these enterprisesis FAN gGmbH, a research organiza-tion for applied neurosciences. Partof the MTA from FAN gGmbH aretrained by the Fit-Bildungs-GmbH.This educational provider specializingin medical-technical assistant professi-ons attaches great importance toinnovative educational concepts. Thisis why it came to test the use ofvirtual-interactive models for trainingjointly with Fraunhofer researchersfrom the Virtual Develop ment andTraining Centre VDTC.

Virtual technologies hold great potentials for the sector of technicalstaff education and training. Three-dimensional contents open completelynew possibilities to exchange informa-tion and transfer knowledge in virtualenvironments. Virtual 3-D modelshave impressive advantages over areal environment such as the unlimit -ed availability of a virtual learning orwork environment, the reversibilityof learning actions and the didacticreducibility of real facts to corecontents by means of time lapse,transparencies or sectional planes.In addition, virtual models are especi-ally clear and thus easily understand -able for users. This realization hasalready found acceptance in manyrealms of industry. Three-dimensionaland interactive representations ofvirtual models are already standard inengineering and design, for example.

Experiments in the Virtual LabThe project partners jointly developeda software proto type conceived as amodel for the advanced training ofmedical-technical laboratory assistantsworking in neuromedical researchlabs. To develop the software, theproject partners first step was todefine a representative analysisprocedure. This customized virtual-interactive 3-D scenario teaches MTLAhow to produce preparations fromthe brains of test animals and howtest series are prepared, executedand analyzed. The experiments shownhere support research on variousaspects of stroke treatment.

The procedure was subsequentlysubdivided into four separate mod -ules. The first module, perfusion,includes the fixation of tissue followedby the extraction of the test prepara-tion, i.e. the extraction of the brain.The subsequent tissue preparation(second module) covers the postfixa-tion and preparation of wafer-thintissue slices with the cryostat. Thethird module covers the immunhisto-chemical reac tion. In this process, adye makes the structures of the antigens visible. This is how the tissue sections are prepared for laterana lysis. The analysis of the dyedstructures under the microscopefollows in the fourth module.

Perfusion fixation of a test animal.

Applying the primary antibody to the tissue section.

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The main objective was to first transferthese modules to a virtual 3-D learningenvironment, taking into account theclose correlation between the contentof individual modules and the impacton the results of analysis. Therefore,the individual modules were assignedto different local workstations in avirtual lab. Thus, both the specifics ofthe individual process steps per work-station (spatial separation) and theirlinks to the complete analysis proce-dure can be represented. As a result,along with being able to work on aspecific module (e.g. procedural step)at any time, trainees are also able tofit the content into the overall contextof the analysis.

When they do not use the VR educa-tional modules, trainees only reallycomprehend the overall proceduremuch later. A training process in a reallab usually has only one piece ofequipment on hand, which is usedduring ongoing operations.

Accordingly, the MTLA usually do notcomplete the process in the propersequence but rather depending on theavailability of the necessary equip-ment. Thus, insights based on princi-ples of cause and effect are lost andthe consequences of mistakes are notapparent. Either a colleague instead ofan individual trainee has produced thepreparation or the preparation wasproduced so long before that traineeshave already forgotten any potentialerrors.

How the VR Educational ModuleFunctions:An introduction familiarizes users withworking with the system and the chainof analysis. In every module, users canview demonstrations of preparatorysteps for work (e.g. instruments invol-ved, chemicals). The presentationmode subsequently shows trainees anideal approach, whereupon textinstructions enable users themselves tointeract with the virtual models. Auser’s level of interaction has been

Tissue preparation in the cryostat.

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adaptively coupled with the particularlevel of difficulty of a procedural step.While a relatively high level of inde-pendence is required to complete diffi-cult job steps, the presentation modesuffices for simple educational con -tent. The entire analysis procedure iscompleted with a complex test con -sisting of practical and theoreticalsections.

Test Phase and Test ResultsIn a test phase, the Fit-Bildungs GmbHtested the interactive 3-D module’stransfer of knowledge in the trainingprocess. They focused on the extent towhich the software’s content anddidactic structure is suitable for know-ledge transfer and the degree towhich it can contribute to the develop-ment of professional skills. What ismore, issues of ease of operation andacceptance were integrated in the test.Three test groups were formed toconduct practical tests with traineesfrom Fit-Bildungs-GmbH.

Group 1: Participants with sound workingknowledge of computers and standardsoft ware who also have personal expe-rience navigating computer games butno prior medical knowledge (e.g.medical docu men tation assis tants).

Group 2: Participants from the professional envi-ronment of medical-technical lab assis -tants who already have medical labknow-how but little or no experienceworking with computers.

Group 3: Participants with sufficiently goodworking knowledge of computers and prior medical knowledge, whichhowever is not connected to specifictechnical lab work (e.g. physio therapytrainees).

Each test group received individualorientation on working with the soft-ware. In particular, the test subjectswere familiarized with its didacticstructure and user prompting. This wasfollowed by the practical test phase inwhich participants independentlycompleted the training module with-out a time limit. Questionnaires andinterviews were employed to subse-quently assess the test phase.

So far, the test results have confirmedthe correctness of the approach. Thetest persons grasped the complexity ofthe facts despite the didactic reduc-tion. Relevant process flows werereflected correctly in the overall struc-tured module. In practical training inthe teaching lab, it is already becom -ing apparent that participants havenoticeably increased skills handlingequipment after they have completedthe interactive training. The test resultsdemonstrate that interactive trainingmodules hold great poten tial to sup -port the training of medical-technicalprofessionals, which is generalizablefor other professional fields too.

Contact:Wolfram SchoorVirtual PrototypingTel. +49 (0) 391/4090-147Fax +49 (0) 391/4090-115Wolfram.Schoor@iff.fraunhofer.de

Work on this project was supported bythe Federal Ministry of Education andResearch BMBF as part of its InnoRegioinitiative (ref. no. 0310422A and0310422B).

Analysis of the structures detected under the microscope.

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Virtual Machine ConfigurationBased on a Modular PrincipleDr. Tamara Nestorovic and Ronny Franke

Constantly changing market requirements demand plant manufacturersquickly responsd and quickly adapt their products accordingly. Applyingmethods of virtual reality to the field of mechanical engineering holdsgreat potential to strengthen manufacturing-oriented enterprises as theymove toward adapting to the market more rapidly. To do this, researchersfrom the Fraunhofer IFF have developed a sys tem for VR Based TechnologyDevelopment and Machine Configu ration (VITECMA).

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VITECMA primarily supports technolo-gists and marketing experts in theirwork. Developers of technical assetsobtain an easy to operate tool fordesign, simulation and optimizationfor the purpose of holistic productdevelopment. Configurable VR mo delsmake product marketing easier andthis can shorten the bidding phase.Manufacturers can already presentclients a concrete model of theirpotential equipment the first time they meet. Buyers of equipment canalready identify potential difficulties inadvance and consequently accelerate a ma chine’s commissioning.

VITECMA is based on methods of vir -tual engineering for technology devel -opment and plant system configura-tion. The system combines severalaspects of product development suchas configu ration, simulation, sequenceplanning and visualization in one plat -form. This new tool is an extension ofthe Fraunhofer IFF’s proven VirtualDevelopment and Training Platform(VDT Platform), specifically for mecha-nical engineering.

A customized compo nen t libraryenables users to design new equip-ment in the briefest time while incor-porating specific customer demands(see illustration). High user friendlinessalso enables non-engineers to virtuallydevelop machi nery. A concrete modelof a piece of equipment can beassembled by dragging and dropping.In the process, users can resort to so-called snaplines, a support tool toquickly and optimally position indivi-dual components. This makes hand-ling considerably easier. A predefinedlogic behind the snaplines ensuresthat only “sensible” positions of com -ponents are marked. Thus, users, forexample sales staff, can assemble aconcrete 3-D model of their equip-ment relatively quickly and uncompli-catedly, which can subsequently be“walked through” virtually in talkswith clients. This informs potential

Virtual user interface with component library.

(FEM) can be integrated in a visualiza-tion and provide additional insights.

The new tool has proven to be ex -ceedingly useful in factory planningtoo. Thus, for example, local condi -tions, already existing equipment orinterference factors such as columnsor stairs can be transferred into thevirtual environment. Newly plannedequipment can then be embedded ina factory building while incorporatingsafety para meters and optimal roomuse and supplemented by necessaryperipherals. Even entire assembly linesor machining centers in new factorybuildings can be planned in shorttime. Work stations, ma chinery andconveyor systems can be positioneddifferently virtually and their efficiencyand accessibility can be tested before

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one chair is even moved in reality. Anintegrated measuring tool furnisheshelpful services. It can be used todefine and designate hazardous areassuch as a robot’s workspace.

VITECMA supports holistic productdevelopment. Along with a designreview of planned equipment, func-tions and machining processes can bedepicted. In addition, planned manu-facturing processes can be simulatedon the model and machine parame-ters or component properties can betested. Structured documentation ofthe requisite equipment and toolcomponents as well as their support -ing data (times, cost, energy consum -ption, etc.) support a visualization. Asingle-column milling machine madeby SCHIESS GmbH was used to suc -cessfully test the approach described.What is more, the system supportsautomated generation of a productdata sheet that compiles all importantequipment information, includingevery hidden componen t. In combina-tion with a previously generatedimage, the datasheet can be used togenerate high recognition value.

With VITECMA, the experts at theFraunhofer IFF have created a systemthat is interesting both for marketingstrategists and technologists.Marketing professionals profit fromthe presentation and configurati onfunctions that enable them to answerspontaneous inquiries from customerswithout necessarily having to have atechnologist’s know-how. As a result,manufacturers can significantly shor-ten the offer phase for their products.The system can be used to easilycompile a database in which everypossible combinati on of their range ofproducts is available in visualizedform. This additionally minimizes workplanning equipment with the same orsimilar designs. At trade show appea-rances or in sporadic talks with custo-mers, manufacturers or their salesrepresentatives can access the data-base very quickly and easily.

buyers about the feasibility and poten-tial follow-up costs of a new acquisi-tion faster.

To plan the production of particularend products, manufacturing stepsand machining operations can begene rated and tested directly in a 3-Dmodel. In this way, the functions ofplanned equipment can be tested forpotential pro blems or boundary condi-tions at an early stage.

Additional, externally generated infor-mation can also be represented alongwith the configured machine. Forinstance, the results of calculationssuch as the finite element method

Schematic diagram of the VITECMA sytem.

Moreover, automatically generateddatasheets can be sent to potentialcustomers in an email. On the otherhand, VITECMA also supports cus -tomers’ engineers when they arecommissioning new equipment. Thesystem can simulate manufacturingprocesses in real time and thus detectfaults at an early stage.

Fifty percent of the VITECMA projectwas funded by the “Mittelstands -initiative Sachsen-Anhalt”.

Contact:Dr. Tamara NestorovicVirtual EngineeringTel. +49 (0) 391/4090-108Fax +49 (0) 391/4090-115Tamara.Nestorovic@iff.fraunhofer.de

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Really Controlling Virtual MachinesMarco Schumann and Torsten Böhme

The increasing complexity of machines is demanding significantly more timeand effort to commission them. At the Fraunhofer IFF Virtual Developmentand Training Centre VDTC in Magdeburg, components of a machine controlsystem can be tested on a virtual model of a machine before the real machinegoes into operation.

© V

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The manufacture of automated manu-facturing equipment such as machinetools or special machines is character -ized by intense cost and time pressureand simultaneously increasing de -mands on product quality . The timeand effort required to develop andmanufacture new products is evolvinginto a crucial competitive factor. Notonly product development but alsoservice, training and marketing areincreasingly playing a role.

For the most part, automated manu-facturing equipment is developedsequentially. The steps of mechanicaldesign engineering, electrical designengineering and control system devel -opment are completed successively.Control software in particular is devel -oped and first tested on the realmachine. The increasing com plexity ofmanufacturing equipment is causingproblems ever more frequently.Mistakes from earlier stages of devel -opment often only become apparentwhen a machine is commissioned.This generates further iterative cyclesin development and prolongs the timeuntil a machine is commissioned. Inthe worst case, this is connected withex ploding costs. A sound test of thesoftware on the real machine is oftenimpossible for reasons of time.

Virtual Models in the Product LifeCycleInteractive visualizations and simu -lations enable using a computer toclearly and realistically reproduce com -plex structures and processes. Virtualmodels can already convey a compre-hensive, three-dimensional impressionof a product in early phases of devel -opment. The preliminary design canbe tested, dimensions can be checkedand potential error sources can beidentified before implementation.Consequently, a key field of applica-tion is the use of digital models forthe integrated planning, validationand control of product developmentpro cesses. Moreover, interactive visualization andsimulation are increasingly growing inimportance for sales since interestedparties can be given a convincingimpression of a finished machine or acomplete system even before makinga purchase. In the planning anddesign phase, a machinery manufac -turer’s client can be involved in thebroader development and pro ductionprocess so that the product producedis customized for a client’s specificneeds.

Creating Virtual Models fromExisting DataThe time and effort that go into creat -ing virtual models and incorporatingthem in existing VR sys tems is stillrelatively substantial though. Special -ized software solutions exist for manyapplications, which predominantlyemploy their own data formats.Frequent data conversions into differ -ent formats are laborious, may beafflicted by data loss and often onlyable to function in one direction. A 3-D CAD system and VR systemsinterface is a typical example. A CADsystem operates with parameterizedvolume data for example. However,the overwhelming majority of VRsystems employ polygonal surface mo dels for visualization. ComplexCAD data can often only be trans -ferred into a VR system after greatsimplification. Modifications of thedata in the VR system during a designreview often cannot be returned to aCAD system at all and when they canthen only with much work.

Integrated use of virtual models in development, operation and training as well as for presentations.

com po nents (CNC or SPS programsfor instance) into the programmingcode for the VR system. The workrequired is so great in practice that itoutweighs the potential benefits of VR supported training systems and isthus one of the reasons why only arela tively low number of VR basedtrain ing systems are in use so far.Here too, the team of researchers at the Fraunhofer IFF succeeded indeveloping a new approach, whichmakes already existing electronicinformation used in product develop-ment available in a virtual environ-ment. This approach is describedbelow in the section “Coupling a RealControl System with the VirtualModel”.

Functional Tests on the VirtualModelSo that the commissioning phase doesnot act as a factor prolonging theoverall development time of equip-ment, the ability to perform functionaltests at as early a time as possible isadvantageous. In practice, a func -tional test can only be performedwhen the design engineering hasbeen completed. Only when a virtualprototype is used can several develop-

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ment tasks proceed simultaneously(simultaneous engineering). The func-tional test can already be started ondigital models in the virtual environ-ment while the machine is still beingmanufactured.

From the perspective of the engineersinvolved, a functional test in a virtualenvironment requires merging twomodel worlds. On the one hand,design engineers have their CADmodel world. The CAD models haveto be transferred to the virtual envi-ronment and be “revivable” by akinematic simulation. This means thatthe degrees of freedom in the move-ment of individual components mustbe mapped correctly and thus allow avisualization of the machine’s state.Control engineers need a functionallyoriented model world for their devel -opment work, which reproduces amachine’s performance together withthe control system. This necessitates aperformance simu lation that can reactto externally acting control signals inreal time.

Coupling a Real Control Systemwith the Virtual ModelSpecialists from the Virtual Develop -ment and Training Centre VDTC coupled the fully functioning controlsystem of a heavy machine tool withits virtual model. Connecting the realcontrol system with the virtual modelworld can parallelize the developmentprocess in the technical domains involved.

Design engineers work in their accus -tomed CAD environment. The controlsystems engineers are enabled todevelop their software in parallel onthe virtual model of the machine.They too can already work on the realcontrol system. The virtual model ofthe machine created to do this con -sists of the kinematic model and theperformance model. It reproduces thefundamental characteristics of the ma -chine’s performance. The machine’soperating performance and disturb -ance response can already be tested

Over several years of developmentwork, the Fraunhofer IFF produced atool that allows transferring CAD datafrom commercially available sys temssuch as Pro/Engineer, CATIA orSolidWorks to a VR system also devel -oped by the Fraunhofer IFF. Correctobject names as well as the assemblystructure configured by a designengineer are transferred. Coordinatedmodules support potentially necessaryreworking steps such as preparingdifferent levels of detail, smoothingedges or applying textures. This mini-mizes the work required to generatethe geo metry model.

The geometry model serves as thefoundation to create the functionalmodel, i.e. the mapping of a machineor plant’s performance. An object’sperformance in a virtual model isdescribed in a completely differentprogramming language than, forexample, a CNC machine tool’smotional sequences . If the virtual mo del is intended to be used fortrain ing purposes, it is necessary toelaborately convert the real control

A virtual model of a heavy machine tool taken from a 3-D CAD system.

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during the development phase. Thus amachine can be optimized throughoutthe entire development process.

Operator Training in the VirtualEnvironmentSuch a system can be used beyondthe development process for manyand diverse applications, e.g. operatortraining or CNC programmer training.The virtual machi ne model guaranteesrealistic machine performance. Thismakes training conducted on themachine especially demonstrative.Thus, manufacturers of technicalassets can already provide their cus -tomers virtual trai ning environments,while the real machine is still beingmanufactured. Customers have theadvantage of being able to train theiroperators at an early stage in an envi-ronment in which potential operatingerrors cannot cause damage on a realmachine. This additionally saves valu -able time. Operators have alreadyacquired initial experience handling amachine before it is put into opera-tion.

Connecting the virtual model with thereal control system during the machi-ne’s operation generates other advan-

tages. On the one hand, model para-meters can be obtained from the realmachine’s performance. This is usedto render the machine model moreprecisely so that modifications ofmachine confi guration can be testedand implemented parallel to ongoingoperation. Thus, setup times can beminimized. Likewise, by coupling themachi ne model to the real machine,current operating parameters can bedocumented parallel to machineoperation and the machine’s condi-tion can thus be diagnosed.

Virtual-Interactive ProductPresentation Supports SalesVisual-interactive reproductions ofmachinery and plants can significantlycontribute to efficient pro duct presen-tation and constitute a universalmarketing instrument. Apart fromtheir demonstrativeness, even includ -ing images and videos too, interac-tivity is another extremely importantfeature of product presen tations thatuse virtual methods.

Users can acquire their first immediateexperience with a product and freelymove in the virtual environment toexplore a machine. It is possible to

examine every assembly and everysingle element of a machine, depend -ing on the representation’s level ofdetail. Techniques that make certainmachine components transparent orhide them also make it possible toview internal or difficult to accesselements in the virtual world. If func-tional models underlie the machine’sassemblies, it is possible to move amachine’s individual parts and learntheir functionalities. Naturally, thisallows assembling and operatingcomplete products, machines andplants.

Thus, virtual-interactive represent -ations can effectively present a roduct’s advantages as well as itsdesign and operation. A comprehen -sively designed product scenario canbe used for the widest variety oftarget groups, e.g. sales staff, opera-tor personnel or service staff.

Contact:Marco SchumannCentral ViVERA OfficeTel. +49 (0) 391/4090-158.ax +49 (0) 391/4090-115Marco.Schumann@iff.fraunhofer.de

NC test on an interactive 3-D model of a heavy machine tool. © M. Schumann

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PMO Services: The All-round Talentfor Industrial PlantsDr. Martin Endig and Frank Mewes

In the future, the range of customized services for operators of complex plants will be crucial forsurvival against international competition. Providing innovative documentation, using up-to-date information to systematically support maintenance work or even offering training for specific products are aspects that will be instrumental in attracting new customers and reinforcing existingcustomer relationships. What do product supporting services look like and how can they be implemented in small and medium-sized enterprises (SME) in particular? Researchers at the VirtualDevelopment and Training Centre have developed PMO Services (Plant Maintenance and Operation Services). PMO Services include services essential for establishing product supporting services in SME. The biomass cogeneration plant in Templin is an up-to-the-minute example that illustrates how the Fraunhofer Institute successively conceptualizes and implements customized services.

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It starts with an idea…The researchers at the Fraunhofer IFFplan and develop small and medium-sized power plants up to 20 MW onthe basis of renewable raw materialsand secondary fuels (e.g. waste).Energy conversion plants are fre -quently being operated with lesspersonnel. Responsibility for thoseintegrated in manufacturing or refi-ning processes primarily lies withmachine operators additionallyresponsible for overseeing otherplants. Service information needed foroperation, servicing and maintenanceis located in voluminous supplierdocumentation. Its management isextremely varied or complicated sinceindividual components are rarelypresented from the perspective ofprocessing, servicing or maintenance.Systems engineering support onlypertains to a plants’ control systemsand the monitoring of process-criticalcomponents. An extensive sensorsystem is usually avoided for reasonsof cost. As a result, maintenance-based monitoring cannot be imple-mented at this time.

The biomass cogeneration plant inTemplin (4 MW thermal firing capac -ity) is a model project already imple-mented by the Fraunhofer IFF. Operat -ing the power plant involves taking anumber of measures to secure theplant’s condition and additionally opti-mize the process engineering. Thesemeasures require information aboutthe plant itself and the process engi -neering. This data is generated in theengin eering process and compiled intechnical documents, among otherplaces. Other documents required forapproval and operation are added.What is more, spare part catalogsnecessary for particular servicing andmaintenance measures are compiled.The general contractor compiles allthis information and these docu-ments, edits them and delivers themto the operator along with the plant.Here lies the big problem: As a rule, aplant operator receives informati on

and technical documents on paper,which can only be used to a limitedextent because the documents arequite extensive and unmanageable.This increases the time spent search -ing for relevant information. In theend, servicing and maintenance workis more time intensive than planned.

Supporting systems such as mainte -nance planning and control systems(IPS) or document ma nagementsystems (DMS) can only provide aremedy when the operator hassupplied them with relevant informa-tion beforehand. Small and medium-

The biomass cogeneration in Templin. The plant must be serviced regularly. © F. Mewes

The point of departure for all servicesis the setup of a standardized andintegrated information and knowl -edge storage system used to record,interpret and provide service informa-tion and documents relevant for theoperation of plants. This is done bydirectly integrating a 3-D virtual plantmodel, which, among other things,makes new forms of visu alization oftechnical knowledge possible. According to analyses done by theFraunhofer IFF, an abundance of data,information and documents exis ts inenterprises, which can be consolidat -ed in an informa ti on and knowledgestorage system. The innumerabletechnical documents from product documen tation such as circuitdiagrams and drawings are at the verytop. Servicing and inspection cyclesrequired for maintenance also add tothese however. Moreover, an exten-sive spare parts catalog exists forevery plant. An important point hereis the collection of know-how. Thisinformati on is rarely put on paper.Rather, it is usually passed along

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orally. Today, know-how can bestored in knowledge storage systemsand is thus accessible to everyone allthe time. The Fraun hofer experts havedeveloped a suitable model for this.

The provision of a standardized infor-mation and knowledge storage systemis necessary because the availability ofrelevant technical knowledge stillvaries greatly. Information at thebiomass cogeneration plant inTemplin was on hand partly on paperand partly on digital data media andranged from compiled documents tocollections of loose sheets of paper.Documents have the capacity to statetechnically complex facts very confus -ingly. Texts, images and 2-D drawingsonly vaguely reflect the inner life of acomplex plant. In addition, manufac-turer documentation is not based onuniform standards. Companies stillconsider “documentation” and the“provision of service information” aninconvenient obligation. 70 to 75percent of documents and informa-tion are produced by subcontractors

sized enterprises in particular rarelyuse such systems though. Today, allthe information needed to support aservicing process for example ishunted for manually: Maintenancecycles from an IPS, current operatingdata from a centralized control systemand necessary spare parts and installa-tion diagrams from technical docu-mentation. Here lie potentials for opti-mization in the future: The supportingprocesses for a plant’s operation willhave be supported by a standardized,integrated information and knowl -edge storage system. Taking this basisas the starting point, relevant data willhave to be interpreted and visualizedwith new methods, concepts andtechno logies. The goal is to presenttechnical knowledge so that users“grasp it more easily” to thus supportprocesses in real time.

Operators have the overall responsi -bility for the measures taken in plants.However, hardly any time remains inaddition to their day-to-day businessto fully tap the potential to optimizeservice processes. This represents anopportunity for plant manufacturersto develop plant supporting servicesthat help customers cut time andcosts. PMO Services makes this possi-ble. For example, condition-basedmaintenance strategies can result inincreased machine availability andreduced down times among otherthings. The final outcome is hiddenpotentials for revenue and growth.

… and an innovative solution issoon found Researchers at the Virtual Deve lop -ment and Training Centre VDTC havedeveloped PMO Services to plan andimplement plant supporting services.PMO Ser vices encompass the concep-tion, implementation, provision andoperation of plant supporting serviceswithin product service.

Flow simulation of a drying chamber: Representation of velocity distribution.

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and delivered to the general contrac-tor. Suppliers all prepare documenta-tion independently as they see fit.Consequently, a plant operator ex -pends considerable additional workand money to collect and use theabundance of different information.Precisely this presents manufacturersan opportunity to better retain cus -tomers and boost revenue andgrowth.Companies will still not have stand -ardized, supporting services to sup -port the operation of plants in thefuture. Rather, they will depend onthe inform ation and documents avail -able as well as on the specific plantitself and its operator model. Hence,the creation and implementation ofappropriate services will necessitateincorporating the following aspectsfrom the very beginning:– Demand analyses and strategy

development: The first step is in-depth analysis of processes, infor-mation and organizational struc -tures within an enterprise.Recommendations for action andaction plans for the future can bederived from the results. TheFraunhofer IFF provides develop-ment of product service strategiesas they are needed.

– System development, implementa-tion and operation: Efficient inte -gration, interpretation and provi-sion of relevant service informa ti onis only possible with special soft -ware solutions that Fraunhoferspecialists create on the basis of anenterprise’s specified parameters.

– Systems for demand-orientedservice: The goal is to intensifycoupling service activities with thedemands on plants. The procedureis incremental, from plant model -ing to data provision up throughplant model integration and valida-tion (test evaluation). In addition,the researchers also guarantee theoperation of the software and pro -vide technical support as required.

– Qualification and training:Successful implementation of plantsupporting service is a long-termjob that can only be done incooperation with all organizationswithin an enterprise. Integratingand continuously qualifying everyemployee plays a crucial role.

PMO Services in PracticeTo effectively support the operation ofthe biomass cogeneration plant inTemplin by providing up-to-dateservice infor mation and documents,the actual conditions were analyzed.The avail able documents and infor -

mati on were the basis for determiningfuture requirements on the productand its user. The analyses revealed:

– The integration of plant compo-nents provided by differentsuppliers with different control andinformation systems is a funda-mental problem. At this time, thedifferent systems make standard -ized access of service informationon the components impossible oronly possible with considerableadditional work and cost.

Service technicians directly access service information wherever they are working. © H. Tepper

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– In the future, plant operation willbecome a secondary job. Hence,knowledge about a plant is nolonger part of a plant operator’sprimary knowledge. Infor mation,documents and technical know-how must be all the more availableelsewhere and easily retrievable.

Based on these boundary conditions,the first step was defined togetherwith the operator: Providing a newservice solution to integrate, visualizeand provide technical docu ments andinformation in order to better utilizethe existing data. The outcome will bean offline version of this solution deliv -ered to the operator.

A special feature is the direct integra-tion of virtual reality tech nologies tovisualize complex, technical facts. Thisnot only includes the VR based inter-face to access service information butalso the provision of visual-interactivecontents from manuals and installationinstructions. Such technologies canvisualize complex operations “moreefficiently” than classical documenta-tion aids. What is more, digital serviceinformation facilitates user-specificgeneration of VR based contents.

A Look into the FutureState-of-the-art product service solu -tions for technical assets enable bothmanufacturers and operators to devel -op new potentials for revenue andgrowth. In the future, such serviceswill become an important sales argu -ment, particularly for plant designers.PMO Ser vices encompass the concep-tion, implementation, provision andoperation of plant supporting serviceswithin product service. Naturally, theservices are customized for a plant orits respective operator model. Theexample of the biomass cogenerationplant in Templin demontrates howcollaboratively creating customizedsolutions by integrating every partyinvolved is essential today. It further

All information from the extensive product documentationwas prepared to be manageable and user friendly.

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demonstrates that the implementationof such a solution was merely a firststep. A standardized information stor-age system provides “all” service infor-mation and documents. The next stepis to systematically interpret theexisting operational data in order toidentify and prepare necessary mainte-nance measures. This will only bepossible when know-how is collectedand provided. This know-how can help“automatically” define in advancewhat maintenance measures areneeded for specific plant compo nentsat what time. Suitable mo dels andstrategies are already available today.

Contact:Dr. Martin EndigProcess and Plant EngineeringTel. +49 (0) 391/4090-120Fax +49 (0) 391/4090-93 120Martin.Endig@iff.fraunhofer.de

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Vocational school students in themetals technology program are wellversed with computer games playedout in virtual worlds. They navigatethem easily and confidently. Theexecutive editors at WestermannVerlag wanted to take advantage oftheir enthusiasm for this technologyto teach young people com plexlessons. They have already beenpursuing the concept of learning fieldsfor a while. These are didacticallygrounded and prepared levels ofaction that combine complexproblems worked on in action-drivenlearning situations.

Together with the researchers fromthe Virtual Development und TrainingCenter VDTC of the FraunhoferInstitute in Magdeburg, a specialeducational software entitled “MetalsTechnology: Basic Knowledge” waswritten for the metals technologyproduct line. An interactive educa -tional CD-ROM supports the concept.The integrated 3-D visuali zation soft-ware BS Contact VRML/X3D made by Bitmanagemant enables studentsto act independently in a virtual workenvironment. This fosters action-driven work and independent learning.

Westermann Verlag Is Banking on e-LearningHeike Kissner

In an e-Learning project for vocational school students, theFraunhofer Institute for FactoryOperation and Automation IFF

in Magdeburg and school book publisher Westermann in Braun-schweig are jointly developing educational modules to support first year vocational programs inmetals technology. An inter activeCD supplements the primary product line of print materi als.

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The educational modules completeddeal with the following topics:– Manual Producing of Components

(with a mixing tank as example),

– Mechanical Producing ofComponents (with an adjustablestop as example),

– Producing Assemblies (with a dril-ling rig as example),

– Producing Simple Controls (with agluing rig as example).

In the future, the CD-ROM willexpand the range of WestermannVerlag materials for vocational train -ing in the field of metals technology.Along with conventional materialssuch as a textbook and a workbook,trainees in their first year of metalsengineering can use the interactivejob orders from these computerizededucational scena rios to completeexercises in their work materials and“grasp” the solutions in a virtual envi-ronment. Trainees are not howeverthe only users of the CD-ROM. Theinteractive educational material alsoprovides metals technology instructorsmany options to organize their lessonsmore understandably. They can workthrough model solutions for a joborder step by step and reconstructthem on a virtual model. Best practicesolutions support discussions on idealapproaches, the virtual model enab-ling exploration of equipment andmodels as well as processes.

A complex disassembly order is exe -cuted on a drilling rig as an example.The lesson together with the assign-ment lays the theoretical groundwork,which can then be applied to andtried out on the virtual model of thedrilling rig. In another exercise, thevirtual model of a gluing jig is coupledwith the jig’s pneumatic diagram. Atrainee can then reproduce everyswitch position of the pneumatics as

well as their transitions in a clearvisualization. Simple machining proce-dures such as drilling holes are con -sistently reproduced comprehensiblyin every step of work, including mark -ing, clamping and machining theworkpiece.

The Fraunhofer IFF’s virtual realityplatform processes state-of-the-artmachinery and plants for developmentor qualification based on their three-dimensional design data. Qualifi cationmostly focuses on com plex tasks forexperienced skilled labor. The chal-lenge in this project was processingthe tasks in the virtual scenarios insuch a way that first year trainees arenot overwhelmed and sustainablyretain the educational contents byinteracting with the model and theprocesses. Together with the expertsform pertinent departments ofWester mann Verlag, educationalscenarios that are fully usable forvocational education have beenproduced in many languages.

The CD-ROM “Metals Technology:Basic Knowledge. Visualized JobOrders. Learning Fields 1-4” fromWestermann Verlag is available inbookstores (ISBN 978-314-364203-0).

Contact: Heike KissnerVirtual Interactive TrainingTel. +49 (0) 391/4090-118Fax +49 (0) 391/4090-115Heike.Kissner@iff.fraunhofer.de

Detail from the educational module “Manufacturing Assemblies with a jig as Example”.

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Augmented Reality in AircraftMaintenance

Dr. Dieter Langer

Augmented reality is a special form of human-technology interaction. Itholds great potential to optimize existing processes and simultaneouslycut costs primarily in after sales. What is more, productivity improves andthe attractiveness of existing services grows.

This technology can be superbly integrated in remote maintenance systems, which can considerably reduce the danger to personnel deployed in mili tary crises for example. This so-called telepresence enables specialists to be virtually present regardless of their location and provide the necessary technical support during service work.

© E

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frame. In the next step, CAD modelsof the helicopter door are insertedinto the display in real time in thecorrect size and position. The mechan -ic’s eye mixes the real and superimpo-sed images so that a combined imageis ultimately perceived, thus augmen-ting the mechanic’s “visual percep-tion” (augmented reality).

AR technology makes high demandson hardware: The video data from the head-mounted camera must berecorded and analyzed. Afterward,the inserted CAD models must bescaled and projected onto a surface.In EADS applications, a me cha nicshould be able to work autonomouslywith the AR system. The video andCAD model are processed by a por -

table computer, which additionallystores all relevant repair and servicinginstructions.

EADS applications also make highdemands on the display (see left-handillustration ). It has to be equallysuited for indoor and outdoor use andnot encumber a mechanic duringrepair work. It has to be lightweight,while simultaneously providing sharpcon trast and intense brightness. Rapidhead movements “smear” a videoimage. To compensate for this effect,the head’s inertial values such asangular velocity and angular accelera-tion must be recorded and processedfor sensor fusion.

Augmented PerceptionThe technology of augmented realitycan, for example, project maintenanceinstructions directly onto an aircraftbeing serviced at a given moment.The parts affected by a repair arevirtually superimposed on the real partin correct size and position. Thus,service technicians can dispense withhaving to carry paper and Web-baseddocumentation with them.

How the Technology FunctionsAR service technicians wear a so-called see-through display and acamera on their heads. The camerafilms the repair sce nario – the rearright door of a NH90 transport helic-opter in the picture shown here – andexecutes an image analysis for every

Principles of AR technology.

An AR visualization enables a traineeto attempt a repair immediately with-out having to laboriously workthrough the product documentationbeforehand. The individual steps of arepair are animated. On the monitor,AR technology superimposes thisinformati on directly on the landinggear. A trainee does not have to inde-pendently establish a relationshipbetween the landing gear and therepair procedure since this function isintegrated in the AR technology.

A context-sensitive representation ofcontents can further relieve a mecha n -ic. In this form of human-technologyinteraction, the contents of repairs areprocessed beforehand and only thoserepairs are displayed that mechanicsthemselves have selected in advanceor can execute directly from theircurrent position. Context sensiti vityfurnishes an additional advantage:Bothersome searches for repair

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instructions are reduced to a mini -mum of time and a mechanic’s workis made easier as a result.

The illustration on the next pageshows an AR application from theservice division. In this case, aug -mented reality makes concealed struc-tures visible. This gives a mechanic akind of “x-ray vision”. A mechaniccan immediately assess whetherdamage visible in the CFRP (carbonfiber reinforced plastic) outer skin ofthe NH90 helicopter is critical orcosmetic. When the damage is critical,the aircraft is immediately groundedor its flight is restricted so that nocostly consequential damage canoccur. When the damage is cosmetic,it is merely covered up and noted forrepair during the next scheduledinspection.

Augmented Reality in the FieldEADS expects advantages from ARtech nology for its training and serviceafter sales divisions. The illustrationabove depicts a repair to an aircraft’slanding gear as it is currently deliveredto customers with the finishedproduct. The illustration on the nextpage shows the same stage of therepair interpreted with AR technology.In order to understand the illustrationabove, a trainee must first read thetext, understand it and establish arelationship to the illustration. Inanother step, a trainee must apply theknowledge learned to a real repair.Regardless of the quality of the docu -men tation, learning skills is a time andcost intensive process.

Conventional representation of a repair to an aircraft’s landing gear. © EADS

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Successful Project WorkFrom January 2004 through June2006, “Advanced Aug mented RealityTechnologies for Indus trial ServiceApplication” were developed andsuccessfully tested in the projectARTESAS (www.artesas.de).

The feasibility of using markerlesstracking methods for industrial serviceapplications was demonstrated. Theprototype of a see-through displaywith a large opening angle was testedand a software package was devel -oped, which supports freely configu-ring and imple men ting methods ofmarkerless tracking.Furthermore, a solution to the prob -lem of AR initialization was found. Amecha nic strikes a predefined initialpose (position and orientation) relativeto the object being repaired.

Globally Acting and ReactingThere is great interest in telemainte -nance systems both for militarydeployment in a crisis and for typicalservice activities. For example, aspecialist in Germany is connectedwith a mechanic on site in Afghani -stan and provides the mechanicsupport in complex repair operations.AR tech nology can be superbly inte-grated in such systems. The videosignal from a mechanic’s head-moun-ted camera enables a spe cialist to bevirtually present at the work site. Themechanic can put the specialist’sinstructions directly into action and bemonitored by the specialist at thesame time.Additionally the mechanic’s line ofvision on the real model can be repro-duced on a virtu al CAD model, whichthe specialist can view locally on amonitor. This would enable thespecia list to provide even bettersupport.

The technology described is especiallyinteresting for military deployments incrises since it can reduce the imme-diate danger to military personnelconsiderably. The advantage gener -ated for civil applications is the abilityto execute even complex repairs atgreat distances with the quality andexactitude necessary and with littletechnical effort.

The national support project ARTESASsuccessfully demonstrated that indus -trial utilization of augmented reality iswithin reach. Successful marketing ofthis technology will require offeringcustomers an integrated overall sys -tem. That system will have to includethe following features:– Inexpensive generation of AR

content,

– Adaptation of the human-machineinterface to user demands and

– Natural representation of ARcontent so that users can fullyconcentrate on their actual activity.

About the AuthorDr. Dieter Langer is Project Managerof VR/AR Technologies in the Divisionof Support Engineering Military AirSystems at EADS Deutschland GmbH.

Contact: Dr. Dieter LangerAR/VR Systems, EADS, Military AirSystems, Customer SupportOperations – PSCG1 81663 MunichGermany

Tel. +49 (0) 896 07-2 71 79 Fax +49 (0) 896 07-2 17 00 Cell +49 (0) 163 693 37 75 dieter.langer@eads.com

Contact for Augmented Reality atthe Fraunhofer IFF:Dr. Rüdiger MeckeVirtual PrototypingTel. +49 (0) 391/4090-146Fax +49 (0) 391/4090-115Ruediger.Mecke@iff.fraunhofer.de

AR representation of a repair to an aircraft’slanding gear. © EADS

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One, two and three years residenciesare offered, which the young academ -ics can finish with a Master’s or doc -torate, depending on the time theyspend here and their interests. Thepro gram’s thematic foci cover the innovative field of applied virtual real -ity and virtual engin ee ring. Three thematic fields can be selected: Virtualproduct development, virtual processcontrol and virtual-interactive training.The young researchers attend classesand research in the institute’s labs out-fitted with high-tech equipment suchas the LogMotionLab or the Elbe Domwith its 360 degree projec tion surface.Modules in soft skills, language cours -

es and confe rence attendance supple-ment their training. The program isbeing carried out in coope ration withOtto von Guericke University Magde-burg and regional indus try partners.

The objective of the training programis to familiarize young researchers,based on their existing competencies,with the latest virtual and augmentedreality technologies and to enablethem to develop new methods applythese technologies in practice.

To this end, an individual personneldevelopment plan is formulated forevery Marie Curie Fellow, in whichlong-term and short-term goals for

future career development and meas -ures to achieve these are defined.These range from the specification ofdetailed training contents to planningthe publication of research findings atinternational confe rences to theacquisition of management skills forresearch and development pro jects.

One important step in this direction isthe integration of the young research -ers in project teams so they can par -ticipate in European research projectsor acquire practical experience inindustry pro jects.

Euro pean Training Pro gram forYoung Researchers

Dr. Eberhard Blümel

Funded by the EU as part of its Marie Curie actions, a training program for young researchers has been running atthe Fraunhofer IFF Virtual Development and Training Centre VDTC since December 2005. During the runtime offour years, twelve young researchers will come to the Fraunhofer IFF from inside and outside Europe. In “ResearchTraining@VDTC” they participate in international research projects and acquire practical experience in industryprojects.

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Carlo Belardinelli

Since August 2006, Carlo Belardinellihas been researching the developmentof acoustic models of technicalsystems to integrate them in virtualengineering platforms for demon stra -tion, eva luation and trai ning systems.These models are used for example invirtual product development to reducenoise from machine tools. CarlosBelardinelli’s qualifications to do thiscome from his study of acoustic-electronic engineering at the Univer -sity of Rome and a research residencyat the University of Cambridge’sSignal Pro cessing Lab. At the VDTC,he is working closely together withthe “Virtual Commissioning” projectteam.

Rui Guimaraes

Rui Guimaraes earned his Bachelor’sin Computer Engineering from theUniversity of Porto and completed aMaster’s of Science in biomedicalengineering at the University ofLondon. At the VDTC, he is research -ing the development of methods,tools and processes to interactivelyvisualize human organs. The results ofhis research will be applied to support

the planning and execution of mini-mally invasive operations. He is carry-ing out his work in conjunction with astate project and in coope ration withOtto von Guericke University Mag -deburg.

Bartlomiej Arendarski

Bartlomiej Arendarski graduated fromthe School of Electronics and ElectricalEngineering at the Technical Universityin Wroclaw with a Master’s thesis onintelligent building systems. Since April2006, he has been studying applica -tions of VR based training for mainte -nance on complex electrical systems.He has already successfully presentedhis initial results to the industry partnerRWE. Another field of his research isthe development of modules for virtualreality-based modeling of intelligentbuilding systems.

Charikleia Sermpetzoglou

Charikleia Sermpetzoglou graduatedfrom the School of Electrical andComputer Engineering at the NationalTechnichal Universi ty of Athens. Shedevoted her Diplom thesis on radarsys tems to the problem of combiningdata originating from different sourc -

es (sensors). Since October 2006, shehas been involved in the developmentof a system to generate and interpre treal-time logistic data streams. Thissystem is part of the projectLogModelLab that can be character -ized as a tool for demonstrating andstudying the effects of logistics con -crete users can expect when theyimplement RFID technology.

Tamas Juhasz

Tamas Juhasz graduated with adegree in computer science from theSchool of Electrical Engineering andComputer Science at the University ofBudapest. His specialization is themodeling and simulation of complexrobotic systems. Since October 2006,he has been working at the Fraun -hofer IFF on the development ofsystems for the interdisciplinary mod -eling and simulation of mechatronicproducts. His findings are directlyentering the Fraunhofer IFF’s researchspecialization of virtual product devel -opment.

Contact: Dr. Eberhard BlümelVirtual Interactive TrainingTel. +49 (0) 391/4090-110Fax +49 (0) 391/4090-115Eberhard.Bluemel@iff.fraunhofer.de

S H A R P M I N D S

44 Sharp Minds

Prof. Michael Schenk, © V.Kühne

Prof. Michael Schenk, Director of theFraunhofer Institute for FactoryOperation and Automation IFF, hasbeen the new VDI State Representa -tive for Saxony-Anhalt since October1, 2006. VDI Board Member Prof.Rainer Hirschberg officially installedhim in office at the VDI StateChapter’s traditional event, the Festder Technik, at the ParkhotelHerrenkrug on October 14, 2006. Thenew state Representative’s first tasksinclude contacting Saxony-Anhalt’sstate government and friendlyengineering associations and fulfillinghis responsibilities at VDI boardmeetings and on the advisory boardof the Regional Chapters.

How Virtuality BecameReality

It is finished. The Virtual Deve lopmentand Training Centre VDTC wascompleted on November 22, 2006,thus opening new possibilities for theFraunhofer Institute Magdeburg andits pro ject partners to immerse evendeeper in the virtual world. If one

looks back to the end of 2004though, the VDTC only existed as amental construct. Eyk Flechtner whonormally works in the Department ofFactory Planning and Logistics wasselected to execute the planning andrealization of this prestigious objectwhile it was still in its nascency. Forthe next two years, Flecht ner wasresponsible for completing the newbuilding together with the architectu-ral firm ACM.

“That wasn’t an easy task,” he con -fesses. At the same time, it was agreat challenge for him too. Today,when Eyk Flechtner makes his roundsthrough the VDTC, he’s filled withpride to have been part of the crea-tion of such an impressive structure.During the construction phase, he hadhis hands full coordinating the numer -ous installation firms and theirworkers. “We had to improvise a fewtimes,” says Flechtner smiling. Thecoordi nation was also so difficultbecause the Fraun hofer IFF put offinstalling equipment until the lastminute in order to have the latest,best available technology when the

VDTC was completed. Flechtner hadto incorporate all these unknownvariables exactly in the planning andexecution of the construction work.Today, the structure stands in all itsgrandeur in Magdeburg’s Port ofScience. Fraun hofer graphic designer BettinaRohrschneider and well-knownMagdeburg photographer ViktoriaKühne took over designing the exte-rior facade of the Elbe Dom, the VRtesting facility in the VDTC.

Together, the two developed aconvincing concept for the exteriorfacade. It had to be visually appealingand artistically represent the work ofthe VDTC at the same time. Amongthe public, the VR testing facility hasthe highest recognition value of anypart of the building. After an intensivebrainstorming phase, a motif wasdecided on. Today, visitors to theVDTC behold a radiant blue exteriorfacade encircled by a gigantic dataglove. The glove in turn symbolically“reaches” for scientific formulae andequations scattered all over thefacade.

New VDI StateRepresentative forSaxony-Anhalt in Office

L. to r.: Viktoria Kühne, Eyk Flechtner and Bettina Rohrschneider, © R. Korpel

Sharp Minds 45

Doctoral Fellowship forIFF Computer Scientist

Kathleen Hänsch, © V. Kühne

Since 1999, the Fraunhofer-Gesellschaft has announced aprogram for female doctoral studentsevery year. The program supportsyoung researchers for three years andis intended to increase the proportionof female researchers in theFraunhofer world.

Kathleen Hänsch from theDepartment of Data and InformationManagement at the Fraunhofer IFFlanded one of the coveted fellow -ships. She prevailed against thirty-three applicants from twenty-fourinstitutes. The young researcher isnow working on her doctoral disserta-tion on “Structuring, Searching andManaging Informa tion in Mechanicaland Plant Engineering ProductService”. The twenty four-year old isresearching means to help users ofinformation systems track down parti-cular information as easily and quicklyas possible.

Having grown up in Magdeburg,Kathleen Hänsch attended Otto vonGuericke University Magdeburg. Acomputer science major, she special -ized in data bases/technical informa-tion sys tems as well as simulation andgraphics. She additionally minored in

power and environmental engineeringand worked as a student assistant atthe Fraunhofer IFF. “I hadn’t thoughtabout a doctorate at all until then,”Kathleen Hänsch confesses. Head ofDepartment Dr. Martin Endig con -vinced her to apply for the fellowship.“With success – my acceptance camefrom Munich one week before Idefended my Diplom thesis,” relatesthe likeable computer scientisthappily. This was apparently a greatmotivation because she graduatedwith virtually perfect marks.

In her free time, Kathleen Hänschsometimes shows an artistic side. Sheis, for example, a trained choir direc-tor. She’s happiest on the weekendthough when her fiancée, a seniormanager at MTU Maintenance inBerlin-Brandenburg, comes toMagdeburg. “Our wedding will betaking place this year,” the doctoralcandidate reveals with a charmingsmile.

Successful Doctorate

Dr. Jens Kroitzsch, © V. Kühne

Hearty congratulations go to Dr. JensKroitzsch from our Process and PlantEngineering Business Unit. A specialistin electrical power engineering,Kroitzsch earned his doctorate fromOtto von Guericke University Mag -deburg in 2006 for his dissertation

“The Brushless Double Fed Inducti onMachine as Generator in DistributedElectrical Power Plants”.

The native of Chemnitz majored inelectrical engineering at the TechnicalUniversity of Chemnitz-Zwickau. Aftergraduating, the engineer started workas a faculty member at the universityin Magdeburg in 1998. Dr. JensKroitzsch came to the Fraunhofer IFFin fall of 2005. The thirty-three yearold’s special interests are renewableenergies and electric vehicles. His re -search previously focused on electricmachines, power electronics and elec-tric power systems. “For me, workingat the Fraunhofer IFF is especiallyappealing,” says Jens Kroitzsch. “It’snot just all about research here butalso about how the results can benefitsociety.”

New Director of theInstitute of Logistics andMaterial HandlingSystems

Since October 1, 2006, Prof. MichaelSchenk, Director of the FraunhoferInstitute for Factory Operation andAutomation IFF, also heads theInstitute of Logistics and MaterialHandling Systems at Otto vonGuericke University in Mag deburg.The newly formed institute whereProf. Schenk also holds the Chair ofLogistics Systems has its origins in thematerials handling program. Theuniversity in Magdeburg has establis-hed itself in this field nationally andinternationally. The university institu-te’s new name signifies the reorienta-tion of content toward logistics andmaterial handling systems, which issupported and advanced by Otto vonGuericke University’s close coopera-tion with the Fraunhofer IFF.

S H A R P M I N D S

46 Sharp Minds

Around 200 graduates and affiliatedlogisticians from all over Germany andmany partner countries gathered inMagdeburg on October 2, 2006 to

Prof. Michael Schenk, © V. Kühne

look back on 50 years of the materialhandling program in Magde burg andto take advantage of the opportunityto also celebrate the reorganizedInstitute of Logistics and MaterialHandling Systems. The Institute forMaterial Handling and for Steelworksat the former College of HeavyMechanical Engineering in Magde burgbegan programs in material handlingand steelwork in 1956. Fifty yearslater, Magdeburg academics wel -comed guests from more than tencountries, including Cuba, Kenia,Russia, Ukraine, China and Japan tothis anniversary party. After a colloquium in the university’sAuditorium 1 presenting the history ofmaterial handling education, currenttrends in research and in dustry as wellas the newly established institute’sprospects, the guests streamed to Fort Mark where, in its historicalambience, they continued their discus-sions, revived shared memories andestablish new contacts for the future.

New Head of Adminis-trative Services at theFraunhofer IFF

Karla Zorn took over as the Head ofAdministrative Services at theFraunhofer IFF on Novem ber 1, 2006.Apart from project con trolling, theforty-nine year old’s expanded sphereof responsibilities includes accounting,human resource management andpurchasing. With a degree in businessadministration, she replaces HelgaMägdefrau, a member of the found -ing Fraunhofer IFF team from 1992,who retired.

Karla Zorn came to the Fraun hofer IFFin 1997. She had applied for a jobopening in facility management.

Karla Zorn, © A.-K. Wassilew

“Actually, I wasn’t really quiet awareof the job requirements for such a“man’s domain,” reveals Karla Zornwith a wink. Yet, precisely thiswoman would prove herself at theconstruction site – as a dis patcher tothe site manager. Later, Karla Zornnot only coordinated the staff’s movebut was also a kind of facility mana-ger for weeks. In 1998, Karla Zornswitched to project monitoring whereshe could follow her real calling. “Myheart and my passion belong tonumbers,” explains the ardentcontroller.

The native of Magdeburg first stu diedbusiness administration and thenheaded to Stendal in 1979. The largeconstruction site for the nuclearpower plant in Arneburg, today thesite of a pulp mill among other things,offered the graduate the careeropportunities she aspired to asmanag er of worker housing. Afterreunification, gastronomy and hotelrywere her second home for severalyears. In 1994, Karla Zorn startedstudying accounting, controlling andtax theory while working.

From Munich to Magde -burg for a Doctorate

The School of Mechanical Engineeringawarded thirty-three year old mathe-matician Norbert Heider his doctoratemagna cum laude on September 7,2006. Heider earned his doctoratefrom the Chair of Logistics Systemsunder Prof. Michael Schenk. After asuccessful defense, the native of Frei -sing was pulled atop a barrel throughthe downtown, followed by his advi-sors Prof. Schenk and Prof. Augustin,colleagues and friends.

Dr. Brigitte Reminger, Prof. Michael Schenk, Dr. Norbert Heider, Prof. Siegried Augustin

(l. to r.) at the doctoral festivities before theOtto von Guericke monument in Magdeburg.

© Private picture

E D I T O R I A L N O T E S

IFFOCUS 2/2006

This magazine appears biannually and is

available free of charge to clients, partners,

employees, media and friends.

ISSN 1862-5320

ISBN 978-3-8167-7314-6

PublisherFraunhofer Institute for Factory Operation

and Automation IFF

Prof. Michael Schenk

Director

Sandtorstr. 22

39106 Magdeburg

Germany

Tel.: +49 391/40 90-0

Fax: +49 391/40 90-596

info@iff.fraunhofer.de

www.iff.fraunhofer.de

www.vdtc.de

Editorial StaffAnna-Kristina Wassilew

Herbert Siegert

Oliver Heyer

Photos, Images and Graphics© Fraunhofer IFF unless otherwise indicated

Title photo: © V. Kühne

Conceptual DesignAnna-Kristina Wassilew

Bettina Rohrschneider

Herbert Siegert

Sabine Conert

LayoutBettina Rohrschneider

TranslationKrister Johnson

PrintingDruckerei Schlüter GmbH & Co. KG

We wish to thank the employees of the

Fraunhofer IFF and our project partners for their

support during the preparation of this publication.

© Fraunhofer IFF, December 2006.

48 Gallery

G A L L E R Y

The Elbe Dom in the newly opened VDTC. The large projec tion system reveals one-of-a-kindviews into the virtual world.

“This testing facility is unique worldwide.”Alexander von Witzleben, Chairman of the Board of Jenoptik AG

© P

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Gallery 49

50 Gallery

G A L L E R Y

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Gallery 51

Lutherstadt Eisleben is located in southern Saxony-Anhalt. You’ll onlyfind the virtual model of the over one thousand year old city at theVirtual Development and Training Centre VDTC though. Architectureand tourism development plans are visualized and evaluated in virtualEisleben, thus giving architects and residents of the city a vivid impressionof changes planned in this UNESCO World Cultural Heritage site whereurban development must be handled sensitively.

52 Gallery

G A L L E R Y

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2006 was the Year of Science. More than 200 events with over 100 partnersfired up Magdeburg residents’ enthusiasm for science and technology. With themotto “Magdeburg Wants to Know”, 2007 will also bring many noteworthyevents such as the Long Night of Science on June 16, 2007.

Gallery 53

O U T L O O K

Outlook 54

Events in 2007

February 1, 2007Virtually Development and Testingand Real Production. PracticalExamples from Medium-sizedEnterprises in Saxony-Anhalt.Magdeburg

February 13 - 15, 2007LogiMat 2007: International TradeFair for Distribution, MaterialsHandling and Information FlowStuttgart

February 21, 2007 Workshop on RFID SupportedConstruction Site LogisticsMagdeburg

February 22 - 23, 2007b2d – Business To DialogMagdeburg

February 28 - March 2, 200753rd Spring Convention of theGesellschaft für Arbeitswissenschafte.V. Magdeburg

March 8 - 9, 2007Simulation and Visualization 2007 (SimVis), Magdeburg

March 15 - 21, 2007CeBITHannover

April 17 - June 19, 200610th Guest Lecture Series: Logisticsas a Field of Work of the Future –Potentials, ImplementationStrategies and VisionsMagdeburg

May 14 - 18, 2007Ligna Hannover 2007Hannover

May 8 - 11, 2007ControlSinsheim

June 12 - 16, 2007GIFA International Foundry TradeFairDüsseldorf

June 12 - 15, 2007transport logistic 2007Munich

June 16, 2007Long Night of ScienceMagdeburg

June 27 - 29, 200710th IFF Science Days: International Conference “Logistics: Intelligence in Manufacturing and Transportation”Magdeburg

June 27 - 29, 2007 10th IFF Science Days: 4th Conference on Virtual Reality“Virtual Reality and AugmentedReality for Engineering, Testing and Operating Technical Systems”Magdeburg

“We rely on high-end workstations from

Schneider Digital.”Fraunhofer Institute IFF

Marco Schumann,Manager of the Central

ViVERA Office

Opteron Model S2Ox-Series, UpgradeableBlack Housing • Double Acoustic Insulation• Front USB & Firewire • AMD Opteron Socket940 (max. 2x Dual Core) • Registered ECCMemory (max. 24GB) • SATA-I/II RAID-0/1Motherboard (10000 U/min) • Dual Socket •PCI Express 16x Mainboard • Extremely QuietHigh Performance Power Supply Unit • DVDDrive • Disc Drive

Naturally: A sophisticated,extremely quite and powerful

workstation with optimallymatched components and

up to four fast Opteron-CPUs and up to 24 GB RAM*

*with Windows 64 Bit and suitable software

Tel. +49 (0) 8025 9930-0 • www.schneider-digital.deEmail: info@schneider-digital.de

Distributor of:

– Development support from virtualprototypes and virtual functionalmodels

– Customized solutions for processengineering

– Virtual-interactive training andemployee quali fication on demand

– Visual-interactive productdocu mentation

Future Technology Opens New Vistas

The digital process chain: From the idea through sales

View your corporate environment three-dimensionally – on a large 360° projection surface. The Virtual Development andTraining Centre VDTC furnishes the infrastructure and its specialists’ know-how so you can use virtual techno logies inyour projects.

– Sales support from virtual product presentation

For more information: www.vdtc.dewww.iff.fraunhofer.de

IFF

FraunhoferInstitut Fabrikbetriebund -automatisierung

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